Interlocking container

ABSTRACT

An interlocking container for the storage and transport of flowable material. The container is provided with a plurality of interlocking top panels. The panels are provided with catches that alternately engage the top and bottom of adjacent panels to prevent the panels from becoming dislodged from one another and to maintain the side panels at an angled orientation relative to the side panels of the container, to prevent distortion of the side panels by hydrostatic pressure toward a circular orientation. The panels define an opening in the top of the collapsible through which a fill head may engage a top cap of a flexible liner provided within the collapsible container, to fill the liner with flowable material.

TECHNICAL FIELD

The disclosed embodiments relate generally to bulk containers for flowable materials and, in particular, to bulk containers having a top defining an open fill area.

BACKGROUND OF THE INVENTION

Cylindrical containers, such as drums, do not maximize floor and pallet space for storage and transport. It would be desirable to provide a container in a cube shape to maximize storage of material on the footprint of a standard pallet.

Conventional rigid containers, such as drums, for the storage and transportation of flowable or fluid materials are bulky and heavy even when not in use. It would therefore be desirable to provide a lightweight container constructed of cardboard or the like. One drawback associated with the use of cardboard is the tendency of cardboard to deform from a square or rectangular cross section toward a circular cross section.

It is known to provide reinforcements to prevent such deformation, but such reinforcements can be complex, heavy, and expensive. It is possible to provide a lightweight container with interlocking top flaps to prevent the container from deforming. Such flaps, however, tend to obstruct the top of the container, limiting access to through the top of the container. It would be desirable to maintain the top of the container free from obstruction, so that a fill head may be inserted through an opening in the top of the container to fill a flexible bag provided within the container.

It would therefore be desirable to provide a lightweight, flexible container that maximizes the surface area of a standard pallet and prevents the container from deforming while a fluid nozzle is inserted through an opening in the top of the container to fill a flexible bag contained therein with flowable material.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described, by way of example, with reference to the accompanying drawings in which:

FIG. 1 illustrates a side perspective elevation in accordance with one embodiment;

FIG. 2 illustrates a side elevation showing the sides and bottom of the outer liner of the container of FIG. 1 prior to assembly;

FIG. 3 illustrates a top plan view of the top of the container of FIG. 1 after assembly; and

FIG. 4 illustrates a side elevation showing the sides and bottom of the inner liner of the container of FIG. 1 prior to assembly.

DETAILED DESCRIPTION OF THE DRAWINGS

A collapsible container for containing flowable materials is shown generally as 8 in FIG. 1. As shown, the container 8 includes an outer liner 10, having a bottom 12, a plurality of side panels 14, a top 16, and a lid 18. Although the outer liner 10 may be of any suitable dimensions, in a preferred embodiment, the bottom 12 is dimensioned to fit on a standard forty-eight inch long and forty-inch wide stringer pallet 20. Preferably, the bottom 12, side panels 14, and top 16 of the outer liner 10 are constructed of a single sheet of triple sided corrugated cardboard, such as that known in the art.

As shown in FIG. 2, a long sheet 22 of such cardboard is die cut in the configuration shown and provided with a plurality of creases 24 to create the bottom 12, side panels 14, and top 16 of the outer liner 10. The creases 24 divide the sheet 22 into a first bottom panel 26, a second bottom panel 28, a third bottom panel 30, and a fourth bottom panel 32. The creases 24 divide the sheet into a first side panel 34, a second side panel 36, a third side panel 38, a fourth side panel 40, and an overhang 42. The creases 24 also divide the sheet 22 into a first top panel 44, a second top panel 46, a third top panel 48, and a fourth top panel 50. As shown in FIG. 2, the first top panel 44 is provided with a first interlock 52. The first interlock 52 has a first span 54 coupled to a first catch 56 and a second catch 58. Second top panel 56 is provided with a second interlock 60 having a second span 62 coupling a third catch 64 to a fourth catch 66.

As shown in FIGS. 1 and 3, the first interlock 52 is frictionally engaged to the second interlock 60 with the first catch 56 frictionally engaged to the bottom of the third catch 64, and the second catch 58 frictionally engaged to the top of the fourth catch 66 in a manner that locks the first top panel 44 in an angled relationship relative to the first side panel 44 and the second top panel 56 in an angled relationship relative to the second side panel 36.

The angling of the first top panel 44 and second top panel 46 relative to the first side panel 44 and second side panel 36 reduces the tendency of the first side panel 34 and second side panel 36 to bulge once the collapsible container 8 is filled with material. As shown in FIGS. 1 and 3, the third interlock 68 of the second side panel 36 is frictionally engaged to the fourth interlock 76 of the third side panel 38 in a manner in which the fifth catch 72 of the second top panel 46 is frictionally engaged with the bottom of the seventh catch 80 of the third top panel 48 and the sixth catch 74 of the second top panel 46 is frictionally engaged with the top of the eighth catch 82 of the third top panel 48 in a manner that locks the third top panel 48 in an angled relationship relative to the third side panel 38.

As shown in FIGS. 2-3, the fifth interlock 84 of the third top panel 48 is frictionally engaged to the sixth interlock 92 of the fourth top panel 50 in a manner in which the ninth catch 88 is frictionally engaged with the bottom of the eleventh catch 96 of the fourth top panel 50. The tenth catch 90 is of the third top panel 48 is frictionally engaged with the top of the twelfth catch 98 of the fourth top panel 50 in a manner that locks the fourth top panel 50 in an angled relationship relative to the fourth side panel 40.

While in the preferred embodiment the seventh interlock 100 is frictionally engaged to the eighth interlock 108, with the thirteenth catch 104 frictionally engaged to the bottom of the fifteenth catch 112, and the fourteenth catch 106 frictionally engaged with the top of the sixteenth catch 114, the fourth top panel 50 may instead not be engaged to the first top panel 44 if a collapsible container 8 with more or less than three side panels 14 is provided. Additionally, the catches may be alternated with the upwardly located catches placed downward and the downwardly located catches placed upward. Similarly, some of the catches may be eliminated so that the remaining catches may be frictionally engaged directly with the main top and bottom surfaces of the top panels 44, 46, 48, 50. Preferably, when all of the catches are engaged, the top panels 44, 46, 48, 50 define an opening 116 preferably at least 5% of the area defined by the side panels 14 or preferably at least 10% of the area defined by the side panels 14, and, most preferably, at least 20% of the area defined by the side panels 14. (FIGS. 1 and 3).

To further reinforce the side panels 14, an inner sleeve 118 may be provided against the interior of the side panels 14. As shown in FIG. 4, the inner sleeve 118 is constructed of a single sheet of triple sided corrugated cardboard, such as that known in the art. A long sheet 120 of such cardboard is die cut in the configuration shown and provided with a plurality of creases 122 creating a plurality of bottom panels 124, side panels 126, overhang 128, and top panels 130. The side panels 126 are preferably of a slightly smaller dimension than the side panels 14 to allow the inner sleeve 114 to fit within the interior 132 defined by the side panels 14. Preferably, the overhang 128 is provided with an adhesive 134 and secured to the opposing side panel 136. Thereafter, adhesive 138 is provided on the overhang 42 and the overhang 42 is secured to the fourth side panel 40. Thereafter, the inner sleeve 118 is provided within the interior 132 defined by the side panels 14. The inner sleeve 118 may be secured to the side panels 14 by adhesive or frictionally secured thereto. The bottom panels 124 and top panels 130 are maintained in an angled relationship relative to the side panels 126 by the interlocking of the top panels 44, 46, 48, 50 in a manner such as that described above, and the interlocking of the bottom panels 26, 28, 30, 32 in a similar manner. If desired, the bottom panels 26, 28, 30, 32 may be provided in a standard trapezoidal configuration, relying on the weight of the fluid provided within the collapsible container 8 to hold the bottom panels 26, 28, 30, 32 against dislodgment. Once the collapsible container 8 has been constructed as described above, a removable flexible liner 140, preferably constructed of polyethylene, such as that well known in the art to hold non-hazardous fluid material, is positioned within the collapsible container 8. Preferably, the liner 140 is provided with a nozzle 142 that extends through a circular cutout 144 provided in the inner sleeve 118, and a similar cutout 146 provided in the outer sleeve 10. Preferably, the nozzle 142 is provided with a collar 148 that prevents the nozzle 142 and collar 148 from passing through the cutouts 144 and 146. The liner 140 is also preferably provided with a top cap 150. The opening 116 in the collapsible container 8 allows a large fill head (not shown) to enter the collapsible container 8 and couples to the top cap 150 to fill the flexible liner 140.

As the flexible liner 140 fills with flowable material 152, such a fruit juice concentrate, tomato paste, or the like, hydrostatic pressure forces the liner 140 against the side panels 126 and downward against the bottom panels 124. This hydrostatic pressure presses firmly against the bottom panels 124 of the collapsible container 8 to prevent the bottom panels 124 from becoming dislodged even if the bottom panels 26, 28, 30, 32 are not frictionally interconnected as described above with reference to the top panels 44, 46, 48, 50. The more flowable material 152 added to the liner 140, the greater pressure on the bottom panels 124 of the collapsible container 8, and the less likely it is that the bottom panels 124 will become dislodged. The interlocking of the top (and if desired, bottom) panels 44, 46, 48, 50, maintains the top panels 44, 46, 48, 50 at an angled orientation relative to the side panels 34, 36, 38, 40 that, in turn, prevents outward bowing of the side panels 34, 36, 38, 40 into a circular orientation. As shown in FIG. 1, once the liner 140 has been filled with flowable material 152, the top cap 150 is closed and a lid 154 is provided over the top panels 44, 46, 48, 50. Although the lid 154 may be of any desired construction, in the preferred embodiment, the lid 154 is a piece of corrugated cardboard provided with side panels 156 angled downward to engage the side panels 34, 36, 38, 40. If desired, the container 8 may then be wrapped with film or adhesive in a manner such as that known in the art.

Although the invention has been described with respect to a preferred embodiment thereof, it is to be understood that it is not to be so limited, since changes and modifications can be made therein which are within the full, intended scope of this invention, as defined by the appended claims. 

What is claimed is:
 1. A collapsible container comprising: a) a first side panel; b) a second side panel; c) a third side panel coupled to the second side panel; d) a fourth side panel coupled to the third side panel; e) a first top panel coupled to the first side panel, the first top panel comprising: i) a top; ii) a bottom; and iii) a first interlock coupled to the first top panel, wherein the first interlock comprises: A) a first catch; B) a second catch; and C) a first span, coupling the first catch to the second catch; f) a second side top panel coupled to the second side panel, the second side panel comprising: i) a top; ii) a bottom; and iii) a second interlock coupled to the second top panel, wherein the second interlock comprises: A) a third catch; B) a fourth catch; and C) a second span, coupling the third catch to the fourth catch; g) a third side top panel coupled to the third side panel; h) a fourth side top panel coupled to the fourth side panel; i) wherein the first interlock is frictionally engaged to the second interlock in a manner in which the first catch is frictionally engaged to the bottom of the second top panel and the second catch is frictionally engaged to the top of the second top panel in a manner that locks the first top panel in an angled relationship relative to the first side panel and the second top panel in an angled relationship relative to the second side panel.
 2. The collapsible container of claim 1, wherein the first to panel, the second top panel, the third top panel, and the fourth top panel comprise a top defining an opening at least 20% of the area defined by the first side panel, the second side panel, the third side panel, and the fourth side panel.
 3. The collapsible container of claim 2, further comprising a fluid nozzle provided in the opening.
 4. The collapsible container of claim 1, wherein the fourth side panel is coupled to the first side panel.
 5. The collapsible container of claim 1, further comprising a flexible bag provided within an interior defined by the first side panel, the second side panel, the third side panel, and the fourth side panel.
 6. The collapsible container of claim 1, further comprising: a) a first supplemental side panel coupled to the first side panel; b) a second supplemental side panel coupled to the second side panel; c) a third supplemental side panel coupled to the third side panel; d) a fourth supplemental side panel coupled to the fourth side panel; e) a first supplemental top panel coupled to the first supplemental side panel; f) a second supplemental top panel coupled to the second supplemental side panel; g) a third supplemental top panel coupled to the third supplemental side panel; and h) a fourth supplemental top panel coupled to the fourth supplemental side panel.
 7. The collapsible container of claim 6, wherein the first supplemental side panel is secured to the first side panel against sliding in relationship thereto.
 8. The collapsible container of claim 7, wherein the first supplemental top panel is in slidable engagement with the first top panel.
 9. The collapsible container of claim 1, wherein a lid is provided over the first top panel, the second top panel, the third top panel, and the fourth top panel.
 10. The collapsible container of claim 1, wherein the second top panel comprises a third interlock comprising: a) a fifth catch; b) a sixth catch; and c) a third span coupling the fifth catch to the sixth catch; d) wherein the third top panel comprises: i) a top; ii) a bottom; and iii) a fourth interlock comprising: A) a seventh catch; B) an eighth catch; and C) a fourth span coupling the seventh catch to the eighth catch; and e) wherein the third interlock is frictionally engaged to the fourth interlock in a manner in which the fifth catch is frictionally engaged with the bottom of the third top panel and the sixth catch is frictionally engaged with the top of the third top panel in a manner that locks the third top panel in an angled relationship relative to the third side panel.
 11. The collapsible container of claim 10, wherein the third top panel comprises a fifth interlock comprising: a) a ninth catch; b) a tenth catch; and c) a fifth span coupling the ninth catch to the tenth catch; d) wherein the fourth top panel comprises: i) a top; ii) a bottom; and iii) a sixth interlock comprising: A) an eleventh catch; B) a twelfth catch; and C) a sixth span coupling the eleventh catch to the twelfth catch; and e) wherein the fifth interlock is frictionally engaged to the sixth interlock in a manner in which the ninth catch is frictionally engaged with the bottom of the fourth top panel and the tenth catch is frictionally engaged with the top of the fourth top panel in a manner that locks the fourth top panel in an angled relationship relative to the fourth side panel.
 12. The collapsible container of claim 10, wherein the fourth top panel comprises a seventh interlock comprising: a) a thirteenth catch; b) a fourteenth catch; and c) a seventh span coupling the thirteenth catch to the fourteenth catch; d) wherein the first top panel comprises: i) a fifteenth catch; ii) a sixteenth catch; and iii) an eighth span coupling the fifteenth catch to the sixteenth catch; and e) wherein the seventh interlock is frictionally engaged to the eighth interlock in a manner in which the thirteenth catch is frictionally engaged with the bottom of the first top panel and the fourteenth catch is frictionally engaged with the top of the first top panel.
 13. A collapsible container, comprising: a) a first side panel; b) a second side panel coupled to the first side panel; c) a third side panel coupled to the second side panel; d) a fourth side panel coupled to the third side panel; e) a first top panel pivotably coupled to the first side panel, the first top panel comprising: i) a first catch; ii) a second catch; f) a second top panel pivotably coupled to the second side panel, the second top panel comprising a top and a bottom; and g) wherein the first catch is frictionally engaged to the bottom of the second top panel, and the second catch is frictionally engaged to the top of the second top panel in a manner that locks the first top panel in an angled relationship relative to the first side panel and the second top panel in an angled relationship relative to the second side panel.
 14. The collapsible container of claim 13, wherein the first to panel, the second top panel, the third top panel, and the fourth top panel comprise a top defining an opening at least 20% of the area defined by the first side panel, the second side panel, the third side panel, and the fourth side panel.
 15. The collapsible container of claim 14, wherein the first to panel, the second top panel, the third top panel, and the fourth top panel comprise a top defining an opening at least 20% of the area defined by the first side panel, the second side panel, the third side panel, and the fourth side panel.
 16. The collapsible container of claim 13, further comprising a flexible bag provided within an interior defined by the first side panel, the second side panel, the third side panel, and the fourth side panel.
 17. A collapsible container, comprising: a) a first side panel; b) a second side panel coupled to the first side panel; c) a third side panel coupled to the second side panel; d) a fourth side panel coupled to the third side panel; e) a first top panel pivotably coupled to the first side panel, the first top panel comprising: i) a first catch having a top; ii) a second catch having a bottom; f) a second top panel pivotably coupled to the second side panel, the second top panel comprising: i) a third catch having a bottom; ii) a fourth catch having a top; and g) wherein the top of the first catch is frictionally engaged to the bottom of the third catch, and the bottom of the second catch is frictionally engaged to the top f the fourth catch in a manner that locks the first top panel in an angled relationship relative to the first side panel and the second top panel in an angled relationship relative to the second side panel.
 18. The collapsible container of claim 17, further comprising: a) a third top panel, pivotably coupled to the third side panel; b) a fourth top panel, pivotably coupled to the fourth side panel; and c) wherein the first top panel, the second top panel, the third top panel, and the fourth top panel comprise a top defining an opening at least 20% of the area defined by the first side panel, the second side panel, the third side panel, and the fourth side panel.
 19. The collapsible container of claim 18, further comprising a fluid nozzle provided in the opening.
 20. The collapsible container of claim 1, further comprising a flexible bag provided within an interior defined by the first side panel, the second side panel, the third side panel, and the fourth side panel. 